Light emitting device assembly and headlamp including the same

ABSTRACT

An LED assembly according to an embodiment of the present invention may improve dark regions generated between LED chips by employing a first reflective layer between the LED chips. By employing a transparent optical layer or an optical layer including a scattering particle between an LED chip and a phosphor layer, direct contact between the LED chip and the phosphor layer may be avoided, thereby preventing a low light extraction efficiency. Further, by employing a second reflection layer on side surfaces of an to LED chip, an optical layer, and a phosphor layer, a relatively high contrast may be obtained. An LED assembly may enhance contrast through a reflective layer while increasing light extraction efficiency by including a scattering particle in a phosphor layer.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.14/151,733, filed Jan. 9, 2014, which claims the benefit of U.S. patentapplication Ser. No. 13/475,486, filed on May 18, 2012, now U.S. Pat.No. 8,882,319, which in turn claims the benefit of Korean PatentApplication No. 10-2011-0046845, filed on May 18, 2011, in the KoreanIntellectual Property Office, the disclosures of each Application isincorporated herein by reference.

BACKGROUND

1. Field of the Invention

The present invention relates to a light emitting device (LED) assemblyand a headlamp including the LED assembly, and more particularly, to anLED assembly and a headlamp including the LED assembly that may obtainhigh contrast while reducing a loss of light emitted from an LED.

2. Description of the Related Art

In general, a vehicle may incorporate a lamp system such as a headlampand a tail lamp to recognize an object in a traveling direction whiletravelling at night and to inform other vehicles or other load usersabout a travel state of the vehicle. The headlamp may be referred to asa headlight, and indicate a lighting lamp that lights a path along whichthe vehicle travels. A daytime running light (DRL) may indicate a lampenhancing perception of a vehicle during daytime hours to reduce a riskof accidents occurring.

An existing lamp for a vehicle may generally have a headlampmanufactured using a light source such as a halogen lamp, a highintensity discharge (RID), and the like. Here, an emitting pattern ofthe headlight is regulated, and an optical design or a physical shieldcutoff of the headlight is used to conform to the regulation.

A light emitting device (LED) may correspond to a semiconductor devicethat generates light by an applied current. The LED may be superior toother light sources in terms of low power consumption, semi-permanentlifespan, fast response time, high light conversion efficiency,stability, environmental friendliness, and the like. Thus, a headlampusing an LED as a light source of a lamp for a vehicle has beendeveloped recently. However, an LED headlamp used for a vehicle is in afirst stage of development, and is being developed slowly.

A light collection structure of a conventional LED headlamp may includean LED light source. a reflector to control a direction of lightgenerated by the LED headlamp, a lens to protect the LED light source,and a physical shield capable of blocking light emitted toward a vehiclefrom an opposite direction and to prevent a glare from the oppositedirection affecting the vehicle.

As described in the foregoing, a light intensity may decrease when acutoff shield is used to conform to regulations for an emitting patternof a vehicle headlamp. Thus, an LED headlamp excluding the cutoff shieldis being developed at an increased rate.

In a structure excluding the cutoff shield, a light emitted from a lightsource may disperse and as such, it may be difficult to obtain a desiredcontrast. In particular, to obtain a high contrast, light generated froman LED chip and being dispersed to a side of the LED chip may beblocked. Here, light extraction efficiency may be an essential elementin the LED light source. Thus, contrast of an LED light source and thelight extraction efficiency may be in a trade-off relationship.

Accordingly, there is a desired for a structure for enhancing contrastof an LED light source while preventing a decrease in light extractionefficiency.

SUMMARY

According to an aspect of the present invention, there is provided alight emitting device (LED) assembly and a headlamp including the LEDassembly that may obtain a high contrast while reducing loss of lightemitted from an LED.

According to another aspect of the present invention, there is providedan LED assembly including a substrate, at least one LED chip mounted onthe substrate, a first reflection layer formed on a side surface of theat least one LED chip, an optical layer formed on the at least one LEDchip, a phosphor layer formed on the optical layer, and a secondreflection layer formed on side surfaces of the optical layer and thephosphor layer.

The optical layer may be formed using a transparent material.

The optical layer may be formed using silicone.

The optical layer may include a scattering particle.

The scattering particle may correspond to silicon dioxide (SiO₂).

An upper surface of the optical layer may be patterned.

The first reflection layer and the second reflection layer may he formedusing the same material.

The first reflection layer and the second reflection layer may comprisea material selected from a group consisting of titanium dioxide (TiO₂),zirconium dioxide (ZrO₂), niobium pentoxide (Nb₂O₅), aluminum oxide(Al₂O₃), magnesium fluoride (MgF₂), aluminum nitride (AlN), and silicondioxide (SiO₂).

The optical layer and the phosphor layer may be formed in a film formand be mounted on the at least one LED chip.

According to still another aspect of the present invention, there isprovided an LED assembly including a substrate, at least one LED chipmounted on the substrate, a first reflection layer formed on a sidesurface of the at least one LED chip, a phosphor layer formed on the atleast one LED chip and comprising a scattering particle, and a secondreflection layer formed on a side surface of the phosphor layer.

The scattering particle may correspond to SiO₂.

An upper surface of the phosphor layer may be patterned.

The first reflection layer and the second reflection layer may include amaterial selected from TiO₂, ZrO₂, Nb₂O₅, Al₂O₃, MgF₂, AlN, and SiO₂.

The phosphor layer may be formed in a film form and be mounted on the atleast one LED chip.

According to yet another aspect of the present invention, there isprovided a headlamp for a vehicle including one of the LED assembliesdescribed above, a reflector to reflect a light generated by the LEDassembly at the front of the vehicle, and a lens to project a lightreflected by the reflector and emitted to an area in front of thevehicle of the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other aspects, features, and advantages of the inventionwill become apparent and more readily appreciated from the followingdescription of exemplary embodiments, taken in conjunction with theaccompanying drawings of which:

FIG. 1 is a perspective view illustrating a light emitting device (LED)assembly according to an embodiment of the present invention;

FIG. 2 is a cross-sectional view cut along the line 14 of FIG. 1;

FIGS. 3A and 3B are diagrams illustrating an optical layer and aphosphor layer in a film or in an LED assembly according to anotherembodiment of the present invention;

FIG. 4 is a perspective view illustrating an LED assembly according tostill another embodiment of the present invention;

FIG. 5 is a cross-sectional view cut along the line II-II′ of FIG. 4;and

FIG. 6 is a cross-sectional view roughly illustrating a headlamp for avehicle according to yet another embodiment of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments of thepresent invention, examples of which are illustrated in the accompanyingdrawings, wherein like reference numerals refer to the like elementsthroughout. Exemplary embodiments are described below to explain thepresent invention by referring to the figures.

Throughout the specifications, when it is described that each of asubstrate, a layer, an element, and the like is formed “on” or “under” asubstrate, a layer, an element, and the like, the term “on” may include“directly on” and “indirectly on interposing another elementtherebetween,” and the term “under” may include “directly under” and“indirectly under interposing another element therebetween.” A standardfor “on” or “under” of each element may be determined based on acorresponding drawing.

Sizes of elements in drawings may be exaggerated for ease ofdescriptions, and do not indicate real sizes.

Hereinafter, a light emitting device (LED) assembly and a headlampincluding the LED assembly according to embodiments will be describedwith reference to drawings.

FIG. 1 is a perspective view illustrating a light emitting device (LED)assembly according to an embodiment of the present invention. FIG. 2 isa cross-sectional view cut along the line I-I′ of FIG. 1.

Referring to FIG. 1 and FIG. 2, the LED assembly 100 according to anaspect of an embodiment may include a substrate 110, at least one LEDchip 120 mounted on the substrate 110, a first reflection layer 130formed on a side surface of the at least one LED chip 120, an opticallayer 140 formed on the at least one LED chip 120, a phosphor layer 150formed on the optical layer 140, and a second reflection layer 160formed on side surfaces of the optical layer 140 and the phosphor layer150.

The substrate 110 may be manufactured using a metal, silicon, orceramic. Here, the substrate 110 may correspond to an insulatingsubstrate manufactured using glass or sapphire, and correspond to aconductive substrate manufactured using silicon (Si), silicon carbide(SiC), or zinc oxide (ZnO). That is, the substrate 110 may bemanufactured using a material having an excellent heat radiationcharacteristic. An electrode (not shown) may be formed on the substrate110, and the electrode may include an electric circuit. Here, power maybe supplied to the at least one LED chip 120 through the electriccircuit.

The at least one LED chip 120 used as a light source may be mounted onthe substrate 110.

The at least one LED chip 120 is briefly described in the following. Theat least one LED chip 120 may include a first conductive semiconductorlayer, an active layer, a second conductive semiconductor layer, and anelectrode. Here, the first conductive semiconductor layer may ben-doped. That is, an electron may be moved to the active layer throughthe first conductive semiconductor layer.

The active layer may be formed on the first conductive semiconductorlayer. For example, the active layer may be formed in a laminatedstructure in which a quantum barrier layer and a quantum well layer arealternately formed so that an electron and a hole may recombine and emitlight. In this instance, composition of the active layer may varydepending on a desired emission wavelength.

The second conductive semiconductor layer may be formed on the activelayer. Here, the second conductive semiconductor layer may be p-doped.That is, a hole may be moved to the active layer through the secondconductive semiconductor layer.

A transparent electrode may be formed on the second conductivesemiconductor layer. As an example, the transparent electrode may beformed on a transparent metal layer such as nickel (Ni)/gold (Au) or beformed to include a conductive oxide such as indium tin oxide (ITO).Here, a p-type electrode may be formed on the transparent electrode, andan n-type electrode may be formed on the first conductive semiconductorlayer. In this instance, the p-type electrode and the n-type electrodemay include various conductive materials such as titanium (Ti)/aluminum(Al), and the like.

A hole may be provided through the p-type electrode, and an electron maybe provided through the n-type electrode. The provided hole and theelectron may combine in the active layer to generate light energy. Theat least one LED chip 120 may correspond to an ultraviolet LED or a bluelight LED depending on a desired wavelength of an emitted light.

The first reflection layer 130 may be formed on a side surface of the atleast one LED chip 120. The first reflection layer 130 may be formedbetween the at least one LED chip 120. The first reflection layer 130may be formed to improve dark regions generated in a space between LEDchips when there exists a plurality of LED chips 120. The firstreflection layer 130 may fill in the space between the at least one LEDchip 120, thereby improving dark regions where luminance deteriorates incomparison to each portion of the at least one LED chip 120.

The first reflection layer 130 may reflect light emitted from a side ofthe at least one LED chip 120 to be delivered to the optical layer 140.

The optical layer 140 may be formed on the at least one LED chip 120.The optical layer 140 may be formed on the first reflection layer 130that is formed between the LED chips when there exists a plurality ofLED chips 120. In this instance, the optical layer 140 may be formed onthe entire surface of the plurality of the LED chips 120 rather thanbeing formed on each of the plurality of the LED chips 120 respectively.Thus, light generated on the at least one LED chip 120 and lightgenerated at a side of the at least one LED chip 120 and delivered bythe first reflection layer 130 may be delivered to the phosphor layer150 through the optical layer 140.

The optical layer 140 may function as a light guide panel that deliverslight generated from the at least one LED chip 120 to the phosphor layer150. The optical layer 140 formed using a transparent material may bedisposed between the at least one LED chip 120 and the phosphor layer150 to prevent direct contact between the at least one LED chip 120 andthe phosphor layer 150, thereby reducing a loss of light.

The optical layer 140 may be formed using a transparent material. Forexample, the optical layer 140 may be formed using silicone. Here, theoptical layer 40 may be formed using a silicone resin having lighttransmissivity of at least 90%. For example, the optical layer 140 maybe formed using at least one material selected from a group consistingof transparent silicone resin composition, epoxy resin, a modified epoxyresin composition, and may not be limited thereto. The optical layer 140may be formed using a transparent material such as glass or aninsulating composition of a plastic synthetic resin.

In an LED assembly according to an aspect of an embodiment of thepresent invention, the optical layer 140 may include a scatteringparticle, and the scattering particle may correspond to silicon dioxide(SiO₂). When the scattering particle is included in the optical layer140, light delivered from the at least one LED chip 120 may bescattered, thereby enhancing light extraction efficiency. An uppersurface of the optical layer 140 may be patterned. When the uppersurface of the optical layer 140 is patterned to havemicro-irregularities, an amount of light lost in the optical layer 140may be reduced, thereby enhancing light extraction efficiency.

The phosphor layer 150 may be formed on the optical layer 140. Here,light emitted from the at least one LED chip 120 may be deliveredthrough the optical layer 140 and emitted to an external environmentthrough the phosphor layer 150.

The phosphor layer 150 may scatter and color-convert colors of lightemitted from the at least one LED chip 120. For example, blue lightemitted from the at least one LED chip 120 may be converted to yellowlight, green light, or red light through the phosphor layer 150 andwhite light may be emitted to an external environment.

The phosphor layer 150 may include a phosphor material that may convertblue light to yellow light, green light, or red light. In this instance,the phosphor layer 150 may include a host material and an activematerial, and include, for example, a material activated by cerium (Ce)in an yttrium aluminum garnet (YAG) host material. A material activatedby europium (Eu) included in a silicate-based host material may be usedfor the phosphor layer 150, and not be limited thereto.

The phosphor layer 150 may be formed to have a thin and uniformthickness. That is, phosphor particles may be uniformly distributed inthe phosphor layer 150. Thus, colors of light penetrating the phosphorlayer 150 may be uniformly color-converted.

FIGS. 3A and 3B are diagrams illustrating an optical layer 140 and aphosphor layer 150 in a film form in an LED assembly according toanother embodiment of the present invention. FIG. 3A illustrates thatthe optical layer 140 and the phosphor layer 150 are separatelymanufactured in film forms, and FIG. 3B illustrates that the opticallayer 140 and the phosphor layer 150 are manufactured in a film form asone body.

In an LED assembly according to an aspect of an embodiment of thepresent invention, the optical layer 140 and the phosphor layer 150 maybe formed in a film form to be stacked on the at least one LED chip 120of FIG. 2. Referring to FIG. 3A, the optical layer 140 and the phosphorlayer 150 may be manufactured separately in film forms to besubsequently stacked on the at least one LED chip 120. Referring to FIG.3B, the optical layer 140 and the phosphor layer 150 may be manufacturedin a film form as one body to be stacked on the at least one LED chip120 in a single operation. Thus, a manufacturing process may besimplified by initially manufacturing the optical layer 140 and thephosphor layer 150 in a film form.

The optical layer 140 and the phosphor layer 150 may be formed byapplying a liquid material onto the at least one LED chip 120 and afirst reflection layer 130 of FIG. 2 and using thermal curing orultraviolet (UV) curing.

Referring to FIG. 2, the second reflection layer 160 may be formed onside surfaces of the optical layer 140 and the phosphor layer 150 toimprove a total luminous flux and obtain contrast in a boundary of alight source portion. That is, when the first reflection layer 130 isformed only between LED chips when there exists a plurality of the atleast one LED chip 120, the second reflection layer 160 may be formed ona side surface of the at least one LED chip 120 at an outermostposition. The first reflection layer 130 or the second reflection layer160 may be formed on a side surface of the at least one LED chip 120 atan outermost position.

High contrast of a light source may be obtained by forming a reflectionlayer on side surfaces of the at least one LED chip 120, the opticallayer 140, and the phosphor layer 150. In an LED assembly according toan aspect of an embodiment of the present invention, the firstreflection layer 130 and the second reflection layer 160 may be formedusing the same material. The first reflection layer 130 and the secondreflection layer 160 may be formed using an oxide that includes one oftitanium (Ti), zirconium (Zr), niobium (Nb), aluminum (Al), and silicon(Si) corresponding to a light reflective material, or be formed using amaterial selected from aluminum nitride (AlN) and magnesium fluoride(MgF₂). For example, the first reflection layer 130 and the secondreflection layer 160 may be formed using a material selected from agroup consisting of titanium dioxide (TiO₂), zirconium dioxide (ZrO₂),niobium pentoxide (Nb₂O₅), aluminum oxide (Al₂O₃), magnesium fluoride(MgF₂), aluminum nitride (AlN), and SiO₂.

In an LED assembly according to an aspect of an embodiment of thepresent invention, contrast may be enhanced by employing the secondreflection layer 160 to prevent light from being emitted to an externalenvironment through a portion other than the phosphor layer 150. Since aseparate shield structure for enhancing contrast may be omitted, a lossof light may be minimized and light extraction efficiency may beimproved.

Although, the configurations may be different from the aforementionedLED assembly, for ease of description, descriptions of structures thatare similar to, or the same as the structures described in the foregoingwith reference to FIG. 1 and FIG. 2 will be omitted, for conciseness, orwill be provided as needed.

FIG. 4 is a perspective view illustrating an LED assembly 200 accordingto still another embodiment of the present invention. FIG. 5 is across-sectional view cut along the line II-II′ of FIG. 4.

Referring to FIG. 4 and FIG. 5, the LED assembly 200 according to anaspect of an embodiment of the present invention may include a substrate110, at least one LED chip 120 mounted on the substrate 110, a firstreflection layer 130 formed on a side surface of the at least one LEDchip 120, a phosphor layer 150 formed on the at least one LED chip 102and including a scattering particle, and a second reflection layer 160formed on a side surface of the phosphor layer 150.

The phosphor layer 150 may be directly formed on the at least one LEDchip 102 and include the scattering particle. When the phosphor layer150 contacts the at least one LED chip 102, light extraction efficiencymay be lowered due to a relatively large amount of light lost in the LEDassembly 200. However, according to the present invention, thescattering particle may be included in the phosphor layer 150 and thus,a low light extraction efficiency may be prevented.

The scattering particle included in the phosphor layer 150 maycorrespond to SiO₂. When the scattering particle may be included in thephosphor layer 150, light delivered from the at least one LED chip 102may be scattered, thereby enhancing light extraction efficiency. In theLED assembly 200, according to an aspect of an embodiment of the presentinvention, an upper surface of the phosphor layer 150 may be patterned.In this instance, when the upper surface of the optical layer 150 ispatterned to have micro-irregularities, an amount of light amount lostin the LED assembly 200 may be reduced, thereby enhancing lightextraction efficiency.

As described in the foregoing, the first reflection layer 130 and thesecond reflection layer 160 may be formed using an oxide, correspondingto a light reflective material, that includes one of Ti, Zr, Nb, Al, Sior be formed using a material selected from AlN and MgF₂. For example,the first reflection layer 130 and the second reflection layer 160 maybe formed using a material selected from a group consisting of TiO₂,ZrO₂ Nb₂O₅, Al₂O₃, MgF₂, AlN, and SiO₂.

The phosphor layer 150 including the scattering particle may bemanufactured in a film form to be stacked on the at least one LED chip120. Thus, a manufacturing process may be simplified by initiallymanufacturing the phosphor layer 150 in a film form, and then stackingthe phosphor layer 150 on the at least one LED chip 120.

FIG. 6 is a cross-sectional view roughly illustrating a headlamp for avehicle according to yet another embodiment of the present invention.

A headlamp having an LED assembly according to an aspect of anembodiment of the present invention may include the LED assembly 100described above, a reflector 310, and a lens 320.

The reflector 310 may be incorporated in the headlamp to reflect a lightgenerated by the LED assembly 100 at the front of the vehicle, and beformed in a predetermined shape to reflect the light to an area in frontof the vehicle. The reflector 310 may be provided in various structures,forms and shapes such as a parabolic shape, a straight line type, and anoptical reflector structure.

The lens 320 may project a light reflected by the reflector 310 andemitted to an area in front of the vehicle of the vehicle. Here, thelens 320 may correspond to an aspheric lens, and may not be limitedthereto.

Accordingly, an LED assembly according to an aspect of an embodiment ofthe present invention may improve dark regions generated between atleast one LED chip, may reduce loss of light, and may obtain arelatively high contrast. An LED assembly according to an embodiment ofthe present invention may omit a shield structure and thus, a headlampfor a vehicle may be manufactured in a relatively simple structure.

An LED assembly according to an embodiment of the present invention mayimprove dark regions generated between LED chips when there is aplurality of the at least one LED chip 120, by employing a firstreflection layer between the LED chips. By employing a transparentoptical layer or an optical layer including a scattering particlebetween an LED chip and a phosphor layer, direct contact between the LEDchip and the phosphor layer may be avoided, thereby preventing a lowlight extraction efficiency.

Further, by employing a second reflection layer on side surfaces of anLED chip, an optical layer, and a phosphor layer, a relatively highcontrast may be obtained.

An LED assembly according to an aspect of an embodiment of the presentinvention may enhance contrast through a reflective layer whileincreasing light extraction efficiency by including a scatteringparticle in a phosphor layer.

Accordingly, an LED assembly according to an aspect of an embodiment ofthe present invention may improve dark regions generated between LEDchips when there exists a plurality of the at least one LED chip 120,reduce a loss of light, and obtain a relatively high contrast.

Although a few exemplary embodiments of the present invention have beenshown and described, the present invention is not limited to thedescribed exemplary embodiments. Instead, it would be appreciated bythose skilled in the art that changes may be made to these exemplaryembodiments without departing from the principles and spirit of theinvention, the scope of which is defined by the claims and theirequivalents.

What is claimed is:
 1. A headlamp for a vehicle comprising: a lightemitting device (LED) assembly; a reflector to reflect a light generatedby the LED assembly at the front of the vehicle; and a lens to project alight reflected by the reflector and emitted to an area in front of thevehicle, wherein the LED assembly comprises: at least one LED chip; areflection layer disposed on four lateral surfaces of the at least oneLED chip, wherein the reflection layer is in direct physical contactwith the four lateral surfaces of the at least one LED chip; and aphosphor layer disposed on an upper surface of the at least one LEDchip, wherein the phosphor layer is in direct physical contact with theupper surface of the at least one LED chip, and at least a portion ofthe reflection layer is contacted with the phosphor layer.
 2. Theheadlamp for a vehicle of claim 1, wherein the LED assembly furthercomprises an optical layer comprising a transparent material.
 3. Theheadlamp for a vehicle of claim 2, wherein the optical layer comprisessilicone.
 4. The headlamp for a vehicle of claim 3, wherein the opticallayer comprises a scattering particle.
 5. The headlamp for a vehicle ofclaim 4, wherein the scattering particle comprises silicon dioxide(SiO₂).
 6. The headlamp for a vehicle of claim 2, wherein the opticallayer is disposed between the phosphor layer and the at least one LEDchip.
 7. The headlamp for a vehicle of claim 6, wherein the opticallayer and the phosphor layer are films mounted on the at least one LEDchip.
 8. The headlamp for a vehicle of claim 1, wherein the reflectionlayer comprises a material selected from the group consisting oftitanium dioxide (TiO₂), zirconium dioxide (ZrO₂), niobium pentoxide(Nb₂O₅), aluminum oxide (Al₂O₃), magnesium fluoride (MgF₂), aluminumnitride (AlN), and silicon dioxide (SiO₂).
 9. The headlamp for a vehicleof claim 1, wherein the reflection layer has an upper surface which iscoplanar with the phosphor layer.
 10. The headlamp for a vehicle ofclaim 1, wherein the at least one LED chip has a lateral surface whichis coplanar with the phosphor layer.
 11. The headlamp for a vehicle ofclaim 1, wherein each of the at least one LED chip, the reflectionlayer, and the phosphor layer has a rectangular shape.
 12. The headlampfor a vehicle of claim 1, wherein the LED assembly further comprises asubstrate on which the at least one LED chip is mounted.
 13. Theheadlamp for a vehicle of claim 12, wherein the at least one LED chip isentirely surrounded with the reflection layer, the phosphor layer, andthe substrate.